CA2550571A1 - Ultrasonically laminated multi-ply fabrics - Google Patents

Ultrasonically laminated multi-ply fabrics Download PDF

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Publication number
CA2550571A1
CA2550571A1 CA 2550571 CA2550571A CA2550571A1 CA 2550571 A1 CA2550571 A1 CA 2550571A1 CA 2550571 CA2550571 CA 2550571 CA 2550571 A CA2550571 A CA 2550571A CA 2550571 A1 CA2550571 A1 CA 2550571A1
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CA
Canada
Prior art keywords
ply
fibers
fabric
outer ply
composite material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA 2550571
Other languages
French (fr)
Other versions
CA2550571C (en
Inventor
Craig F. Thomaschefsky
Larry M. Brown
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kimberly Clark Worldwide Inc
Original Assignee
Kimberly-Clark Worldwide, Inc.
Craig F. Thomaschefsky
Larry M. Brown
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kimberly-Clark Worldwide, Inc., Craig F. Thomaschefsky, Larry M. Brown filed Critical Kimberly-Clark Worldwide, Inc.
Publication of CA2550571A1 publication Critical patent/CA2550571A1/en
Application granted granted Critical
Publication of CA2550571C publication Critical patent/CA2550571C/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
    • B32B37/203—One or more of the layers being plastic
    • B32B37/206—Laminating a continuous layer between two continuous plastic layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/555—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving by ultrasonic heating
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/728—Hydrophilic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/028—Treatment by energy or chemical effects using vibration, e.g. sonic or ultrasonic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2432/00—Cleaning articles, e.g. mops, wipes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2459/00—Nets, e.g. camouflage nets
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24826—Spot bonds connect components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/689—Hydroentangled nonwoven fabric

Abstract

A multi-ply fabric (90) is provided that includes an inner ply (80) positioned between two outer plies (82, 84) that contain both thermoplastic fibers and absorbent staple fibers. The plies (80, 82, 84) are ultrasonically bonded together. The material used to form the inner ply may be selectively controlled to optimize certain poroperties of the fabric (90) for a particular application, such as strength, bulk, absorption capacity, absorption rate, handfeel, etc.

Claims (20)

1. A method for forming a multi-ply fabric, said method comprising:
positioning at least one inner ply between a first outer ply and a second outer ply, said first outer ply and said second outer ply each comprising a nonwoven composite material that includes thermoplastic fibers and absorbent staple fibers, said inner ply comprising a nonwoven layer that includes thermoplastic fibers; and ultrasonically laminating together said inner ply, said first outer ply, and said second outer ply.
2. A method as defined in claim 1, wherein said nonwoven composite material of said first outer ply, said second outer ply, or combinations thereof, comprises less than about 50 wt.% of said thermoplastic fibers and greater than about 50 wt.% of said absorbent staple fibers.
3. A method as defined in claim 1, wherein said nonwoven composite material of said first outer ply, said second outer ply, or combinations thereof, comprises from about 10 wt.% to about 40 wt.% of said thermoplastic fibers and from about 60 wt.% to about 90 wt.% of said absorbent staple fibers.
4. A method as defined in claim 1, 2, or 3, wherein said absorbent staple fibers of said first outer ply, said second outer ply, or combinations thereof, are pulp fibers.
5. A method as defined in any of the preceding claims, wherein said thermoplastic fibers of said first outer ply, said second outer ply, or combinations thereof, are substantially continuous.
6. A method as defined in any of claims 1 to 5, wherein said absorbent staple fibers and said thermoplastic fibers of said nonwoven composite material of said first ply, said second ply, or combinations thereof, are hydraulically entangled or blended.
7. A method for forming a multi-ply fabric, said method comprising:
positioning at least one inner ply between a first outer ply and a second outer ply, said first outer ply and said second outer ply each comprising a nonwoven composite material that includes a spunbond web formed from substantially continuous polyolefin fibers, said spunbond web being hydraulically entangled with pulp fibers, said pulp fibers constituting greater than about 50 wt.%

of said nonwoven composite material, said inner ply comprising a nonwoven layer that includes thermoplastic fibers; and ultrasonically laminating together said inner ply, said first outer ply, and said second outer ply.
8. A multi-ply fabric comprising at least one inner ply positioned between a first outer ply and a second outer ply, said first outer ply and said second outer ply each comprising a nonwoven composite material that includes substantially continuous thermoplastic fibers hydraulically entangled with pulp fibers, said pulp fibers constituting greater than about 50 wt.% of said nonwoven composite material, said inner ply comprising a nonwoven layer that includes thermoplastic fibers, wherein said inner ply, said first outer ply, and said second outer ply are ultrasonically laminated together.
9. The method or multi-ply fabric of claim 7 or 8, wherein said nonwoven composite material comprises from about 60 wt.% to about 90 wt.% of said pulp fibers.
10. A multi-ply fabric as defined in claim 8, wherein said first surface and said second surface form opposing outer surfaces of the multi-ply fabric.
11. A multi-ply fabric as defined in any of claims 8 to 10, further comprising bonded regions having a plurality of contiguous voids.
12. A multi-ply fabric as defined in any of claims 8 to 11, wherein said substantially continuous thermoplastic fibers of said nonwoven composite material are polyolefin fibers.
13. A multi-ply fabric as defined in any of claims 8 to 12, wherein a first surface of said first outer ply and a second surface of said second outer ply each comprise a preponderance of pulp fibers.
14. The method or multi-ply fabric of any of the preceding claims, wherein said thermoplastic fibers of said nonwoven layer are substantially continuous.
15. The method or multi-ply fabric of any of the preceding claims, wherein said nonwoven layer of said inner ply includes greater than about 50 wt.%
thermoplastic fibers, and preferably greater than about 90 wt.% thermoplastic fibers.
16. The method or multi-ply fabric of any of the preceding claims, wherein said nonwoven layer of said inner ply further includes absorbent staple fibers.
17. The method or multi-ply fabric of claim 16, wherein said nonwoven layer of said inner ply includes greater than about 50% wt.% absorbent staple fibers, and preferably from about 60 wt.% to about 90% wt.% absorbent staple fibers.
18. The method or multi-ply fabric of claim 16 or 17, wherein said absorbent staple fibers of said nonwoven layer are pulp fibers.
19. The method or multi-ply fabric of any of claims 16 to 18, wherein said absorbent staple fibers and said thermoplastic fibers of said nonwoven layer are hydraulically entangled or blended.
20. The method or multi-ply fabric of any of the preceding claims, wherein said nonwoven layer of said inner ply has a basis weight of from about 10 to about 200 grams per square meter.
CA 2550571 2003-12-23 2004-06-10 Ultrasonically laminated multi-ply fabrics Active CA2550571C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/745,339 2003-12-23
US10/745,339 US7645353B2 (en) 2003-12-23 2003-12-23 Ultrasonically laminated multi-ply fabrics
PCT/US2004/018875 WO2005068178A1 (en) 2003-12-23 2004-06-10 Ultrasonically laminated multi-ply fabrics

Publications (2)

Publication Number Publication Date
CA2550571A1 true CA2550571A1 (en) 2005-07-28
CA2550571C CA2550571C (en) 2012-11-06

Family

ID=34679124

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2550571 Active CA2550571C (en) 2003-12-23 2004-06-10 Ultrasonically laminated multi-ply fabrics

Country Status (14)

Country Link
US (1) US7645353B2 (en)
EP (1) EP1697121B1 (en)
JP (1) JP5068538B2 (en)
KR (1) KR101200203B1 (en)
CN (2) CN1898080A (en)
AU (1) AU2004314111B2 (en)
BR (1) BRPI0417960B1 (en)
CA (1) CA2550571C (en)
CR (1) CR8430A (en)
ES (1) ES2472266T3 (en)
IL (1) IL175546A0 (en)
RU (1) RU2353523C2 (en)
WO (1) WO2005068178A1 (en)
ZA (1) ZA200604057B (en)

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